Charger for rechargeable batteries

ABSTRACT

A battery charger for charging rechargeable batteries and/or battery packs is disclosed. Preferably the charger can apply two modes of charging a battery. In a normal charging mode a battery is charged to full capacity at a low rate. In a boost charging mode the battery is charged very rapidly and preferably only to a certain degree, such as 75% of its maximum capacity. The boost charging mode makes it possible to provide some charge to the battery when the time available for charging is limited. The boost charging method is based on a very high initial charging current (I init ) The initial current (I init ) is such that a predetermined maximum charging voltage (V max ) is reached almost immediately. The charging current is then decreased in such a way that the charging voltage (V charge ) is maintained substantially constant at the maximum charging voltage (V max ).

The present invention relates to a method of charging a rechargeable unit, such as a rechargeable battery or a rechargeable battery pack.

The present invention also relates to a charger for charging a rechargeable unit, such as a rechargeable battery or a rechargeable battery pack, said charger comprising a supply unit for supplying charging current to a rechargeable unit, terminals for connecting the supply unit to the rechargeable unit, and a control unit for controlling the current supplied by the supply unit.

Rechargeable batteries and rechargeable battery packs have a widespread use in modern life. Many apparatuses, such as mobile phones, battery operated electric shavers, battery powered vehicles, electrical tools etc, are equipped with such batteries.

The rechargeable batteries and battery packs need to be recharged every now and then. There are several types of chargers that can be used for recharging rechargeable batteries. A common type of charger employs a constant current level (CC) throughout the whole charging process of the battery. Fast chargers of this type employ a high, constant current until the battery is fully charged. An electronic unit in the charger is used to detect end-of-charge and cut off the charging current.

The above mentioned CC-charger is useful for charging e.g. NiCd (Nickel-Cadmium) and NiMH (Nickel-Metal-Hydride) batteries. With these batteries the end-of-charge state can be detected as a sudden increase in the temperature of the battery and as a drop in the terminal voltage of the battery.

Lithium batteries (including lithium-ion, lithium-polymer and lithium solid state batteries) cannot be charged by fast chargers of the type mentioned above, since lithium batteries do not provide the above described indications of end-of-charge and since the maximum voltage has to be controlled to avoid damage to the lithium batteries.

U.S. Pat. No. 5,994,878 assigned to Ostergaard et al. describes a charger that can handle different types of batteries, including lithium batteries. The charger may first charge the battery in a constant current mode and then in a constant voltage mode (constant current then constant voltage charging=CCCV). During the first phase of the charging process the charger is in a constant charging current control mode. The charging current is controlled at a preset level and the charging voltage is monitored. When the charging voltage reaches a certain, preset level the charging process enters a constant charging voltage control mode. In this mode the charging voltage is held substantially constant while the charging current is reduced. The charging process as described in U.S. Pat. No. 5,994,878 is however slow and will not allow the quick charging of a battery.

An object of the present invention is to provide a charging method which makes it possible to quickly charge batteries, including lithium batteries.

A further object of the invention is to provide a charger which makes it possible to quickly charge batteries, including lithium batteries.

A charging method according to the preamble is characterized in

that the rechargeable unit is connected to a supply unit;

that the supply unit supplies a current to the rechargeable unit;

that the charging voltage is monitored during charging;

that the initial current supplied to the rechargeable unit at the start of the charging process is such that the charging voltage almost immediately reaches a predetermined maximum charging voltage; and

that subsequently the current is decreased in such a way that the charging voltage is kept substantially constant at the maximum charging voltage during the charging process.

The charging method described above makes it possible to fast-charge different types of batteries and battery packs, including lithium batteries. Since the initial charging current is high in comparison to normal charging, the charge voltage will almost immediately increase to its predetermined maximum level. Consequently the charging current and hence the charge rate is determined only by the internal impedance of the battery resulting in a very short charging time. Thus the battery will be charged at the highest possible current, with respect to the limitation on maximum charging voltage, all through the charging procedure. This allows for high currents at the early stages of charging resulting in very fast charging, in particular at the early stage of charging an empty battery. A typical situation where this has very material advantages is when a user who is just about to leave his home finds out that the battery of e.g. the mobile phone or the shaver is empty. By charging just a few minutes according to the method described above, the person may obtain sufficient battery charge for his needs in e.g. one day. Another example is hybrid electrical vehicles, H(EV), and in particular electrical vehicles. A user who finds the batteries of the vehicle empty may in a very short period of time give the batteries a charge that is sufficient for the ride home.

The measure as described in claim 2 has the advantage that next to all of the charging occurs at the predetermined maximum voltage.

The measure as described in claim 3 has the advantage that the current applied is so high that the voltage almost immediately increases to the maximum charge voltage and thus next to all of the charging occurs at the predetermined maximum voltage resulting in a very high charging current, especially at the early stage of charging an empty battery or battery pack.

Preferably the rechargeable unit is charged to maximally 75% of its maximum capacity, the charging process then being interrupted. Prior art fast chargers have the disadvantage of considerably shortening the cycle life of the battery, i.e. the number of times that the battery can be recharged. The above described inventive method in combination with partial charging will affect the cycle life much less than prior art fast charging. A further advantage of partial charging is that the maximum charging voltage can be increased as compared to normal charging. The battery has been found to be less sensitive to high voltages at the early stages of charging, i.e. when the depth of charge is rather low and the current is high. By employing partial charging, the later stage of charging, where the sensitivity to a high voltage is larger, can be omitted. An increased voltage further decreases the time of charging.

Preferably the initial depth of charge of the rechargeable unit to be charged is measured before charging starts or at the beginning of the charging process, charging being stopped if the rechargeable unit is found to have an initial depth of charge which is higher than a predetermined maximum initial depth of charge. This has the advantage that charging according to the inventive method described above of a fully or almost fully charged battery or battery pack is avoided. Such charging would decrease the cycle life of the battery or battery pack. Thus the user may start a quick charging process at any time and without knowing the initial depth of charge, without any risk of damaging the battery or substantially decreasing its cycle life since charging will be stopped if the battery is already fully or almost fully charged.

The method described above has particular advantages for charging rechargeable units comprising lithium batteries. At present there are no well functioning fast charging methods for lithium batteries. The method according to the invention makes it possible, however, to quickly charge lithium batteries.

A charger according to the preamble is characterized in that the charger further comprises:

means for monitoring the charging voltage;

means for supplying an initial charging current at the start of the charging process of a rechargeable unit, the initial charging current being such that the charging voltage supplied to the rechargeable unit almost immediately reaches a predetermined maximum charging voltage; and

means for decreasing the current in such a way that the charging voltage is kept substantially constant at the maximum charging voltage during the charging process.

A charger of this type makes it possible to quickly charge all types of batteries and battery packs, including lithium batteries. The fact that the charging voltage increases to its predetermined maximum value almost immediately results in quick charging, especially in the early phase thereof, since the charging current is high.

The measure according to claim 8 has the advantage that the user of the charger can choose the charging mode that suits the present situation. If the user is in a hurry he chooses boost charge, e.g. by pushing a corresponding button. If there is plenty of time for charging, the person pushes another button to choose normal charging.

Preferably the control unit comprises means for measuring the depth of charge of the rechargeable unit during charging and means for interrupting the charging procedure at a predetermined depth of charge. An advantage of this is that a certain depth of charge, i.e. charged capacity, may be associated with the boost charging mode. This makes it possible to charge a battery or a battery pack only partially thus avoiding a detrimental effect of the boost charging on the cycle life of the battery. It is also possible to manufacture a charger with a boost charging mode preset for charging to a depth of charge considered to be convenient for the end user.

The measure according to claim 10 provides a simple way of interrupting the charging process. A timer function is cheap and simple to include in a control unit controlling charging and provides a safe way of interrupting the charging process. The timer function is pedagogic in that it makes the charging method easy to use and understand for the end user.

These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereafter.

The invention will hereafter be described in more detail and with reference to the appended drawings.

FIG. 1 is a schematic drawing of a charger according to the invention.

FIG. 2 is a diagram showing the charging principles of boost charging and normal charging.

FIG. 3 is a diagram showing the capacity growth of a battery during boost charging and during normal charging.

FIG. 4 is a diagram showing the charging times for an empty battery at different initial charging currents and different final depths of charge.

When discussing the charging of batteries the expression C-rate is often used. 1 C-rate is the charging current that would be needed to charge an empty battery to its maximum capacity in 1 hour. For each battery capacity a certain C-rate means a certain current.

The expression “boost charging” as used in the present application means a charging method for quickly adding capacity to a battery by charging it.

The expression “normal charging” as used in the present application means a charging method for charging, at a rather slow rate, a battery to its maximum capacity.

The term “cycle life” as used in the present application refers to the number of times a battery can be recharged before it has to be disposed of. A long cycle life means that the battery can be recharged many times.

In the present application “depth of charge” (DoC) refers to the charged capacity of a battery. A DoC of 100% means that the battery has been charged to its maximum capacity.

In FIG. 1 a preferred embodiment of the invention in the form of a battery charger 1 is shown. The battery charger I has a charge current supply unit 2 adapted to supply a desired voltage and current. Terminals in the form of electric cables 3, 4 connect the charger 1 to a battery 5 that is to be charged. Preferably the cables 3,4 are each split up into a current lead and a sense lead for sensing the voltage. The battery charger 1 has a control unit 6 that controls the current and the voltage supplied by the supply unit 2 to the battery 5. The control unit 6 is provided with a selector comprising a first control button, schematically indicated as 7 in FIG. 1, for activating normal charging of the battery 5. The selector further comprises a second control button, schematically indicated as 8 in FIG. 1, for activating boost charging of the battery 5.

Normal charging is activated when the user of the charger 1 pushes the normal charging button 7. Normal charging of the battery 5 is preferably performed according to the constant current/constant voltage method (CCCV-method). Thus the control unit 6 controls the supply unit 2 such that the battery 5 is first charged in accordance with a constant current mode (CC-mode) while monitoring the voltage (i.e. the voltage as measured between cable 3 and 4). The constant current I_(const) during the CC-mode is typically set low such that an empty battery will obtain about 50-90% of its nominal max capacity during the CC-mode. A typical constant current I_(const) for a lithium battery would be 0.7 C-rate, that is a current that, if held constant during 1 hour, would charge the battery to 70% of its maximum capacity. When the voltage reaches after some time the prescribed maximum voltage V_(max) the control unit 6 changes to a constant voltage mode (CV-mode). During the CV-mode the current supplied by the supply unit 2 is controlled such that the voltage is kept constant at V_(max) while the current is allowed to decrease. The control unit 6 stops the charging process when the current has been decreased to a small value or after a predetermined time interval that is sufficient for fully charging the battery. The battery thus charged to its maximum capacity in a slow and cautious manner is ready for use. The normal charging process provides for a long cycle life of the battery and a fully charged battery.

Boost charging of the battery 5 is activated when the user of the charger 1 pushes the boost charging button 8. Boost charging of the battery 5 is performed according to the method of the present invention. Thus the control unit 6 controls the supply unit 2 such that a very high initial current I_(init) is immediately supplied to the battery 5. The control unit 6 monitors the voltage supplied (i.e. the voltage as measured between cable 3 and 4) and controls the current such that the voltage is kept at the prescribed maximum voltage V_(max). The initial current I_(init) is chosen such that the maximum voltage V_(max) is reached almost immediately. The control unit 6 will thus control the current supplied to the battery 5 such that the current is immediately, or after a very short period of time, decreased from I_(init) to a lower value. If I_(init) is very high there will be no constant current phase at all. At a somewhat lower I_(init), still being very high in relation to the current I_(const) supplied during the CC-mode of the normal charging process, a short period of time may elapse before the current is decreased. In either case there is no constant current phase of the type described in relation to normal charging.

It has been found that the initial charging current I_(init) applied in the case of boost charging of lithium batteries should be higher than 1 C-rate, i.e. a current that, if held constant, would charge an empty battery to 50% of its maximum capacity in less than 30 minutes, to provide quick charging. Initial currents I_(init) higher than 2 C-rates, still more preferably higher than 3.5 C-rates, have been found to provide a substantial further reduction of the charging time. It has been found that the initial charging current I_(init) should be chosen such that, at the start of charging, the predetermined maximum charging voltage is reached in not more than 2 minutes, since charging during the first minutes should be performed at a voltage that is as high as possible to decrease the time of charging. It has also been found that the initial charging current I_(init) should preferably be chosen such that the maximum charging voltage is reached in not more than 30 seconds, and still more preferably in not more than 5 seconds, to provide a further substantial reduction of the charging time, charging during the first minute being most efficient if performed at a high current and maximum voltage, still without substantial detrimental effects on the cycle life.

Boost charging may be stopped when the charging current is zero or close to zero. Preferably, however, boost charging is interrupted by the control unit 6 after a short time when the battery 5 is only partially charged. It has been found that boost charging should be interrupted when the battery 5 has been charged to maximally 75% of its maximum capacity (i.e. 75% DoC) to provide quick charging without substantial negative effects on the cycle life, potentially also performed at a higher maximum charging voltage. It has further been found that an interruption of the charging process at a battery DoC of 10-60% provides a relation between time of charging and charged capacity that is attractive for most users of the boost charging function. Thus boost charging is preferably used for quick, partial charging of the battery. To stop boost charging at the proper time for partial charging, preferably a function for measuring the DoC, i.e. the DoC of the battery at a certain time, is included in the control unit 6. The DoC can be measured by measuring battery parameters according to one of several methods that are well known to the skilled person. Examples of such methods of measuring a battery parameter for relating it to the DoC of a battery include open circuit voltage (OCV) measurement and resistance free voltage (RFV) measurement.

The application of boost charging is preferably restricted such that a battery which already has full capacity or almost full capacity cannot be subjected to boost charging. The control unit 6 thus preferably includes a function for measuring the DoC, i.e. the initial DoC, of a presumably empty battery 5 before any charging, and in particular any boost charging, may start. To measure DoC of a battery before starting the charging process use can be made of one of several methods that are well known to the skilled person. Examples of such methods of measuring a battery parameter for relating it to the DoC of a battery include open circuit voltage (OCV) measurement, resistance free voltage (RFV) measurement and battery voltage after relaxation (V_(relax)). It is also possible to measure the DoC at the very beginning of the charging process by measuring the time elapsed before the charging current starts to decrease, provided that the initial current I_(init) is chosen such that a short period of time elapses before the current needs to be decreased to avoid exceeding the maximum charge voltage. The shorter the time before the charging current is decreased, the higher the initial DoC is. It is also possible to measure the slope of the voltage increase over time when starting boost charging, i.e. measure dV/dt. A large dV/dt then indicates a high initial DoC of the battery. If the measurement of the time elapsed before charging current decreases or of the dV/dt reveals that the battery already has a high or full capacity, boost charging is immediately interrupted. In addition to the detrimental effect on the cycle life, the time gained by boost charging at a high initial DoC is so low that it is preferably avoided. Boost charging should not be started, or, if in an early phase, stopped immediately, if the battery is found to have an initial DoC of more than 70% to avoid detrimental effects on the cycle life. The charger 1 may be equipped with a function for indicating that boost charging is interrupted due to high initial DoC, thus showing the user that the battery already has a certain charge. It has further been found that the relation between time of charging and charged capacity adversely affects the advantages of starting a boost charging process at an initial DoC of more than 50%.

In a further example of controlling the charging process is to provide a timer function is provided in the control unit 6. The timer is set to allow boost charging during a certain time, e.g. 5 or 10 minutes, and then interrupt charging. The timer may be combined with the above described function for avoiding charging at high initial DoC and/or the function for interrupting charging at a certain, predetermined DoC. The timer function makes the boost charging function easy to use and understand for the end user.

The control unit may also be adopted to allow boost charging for some time and then switch to normal charging. In such a case the battery is first charged at a high rate for a certain time or to a certain DoC. The charger then switches to normal charging and allows charging of the battery to proceed at a low rate until the battery is fully charged. Preferably an indication, such as the switching on of a LED, is used to indicate that boost charging is finalized. The user may then choose to interrupt the charging process or allow it to proceed in the normal charging mode for fully charging the battery at a slow rate.

Boost charging may be applied to all types of rechargeable batteries. Examples of such batteries include nickel metal hydride batteries (NiMH), nickel cadmium batteries (NiCd), lead acid batteries (Pb-acid), rechargeable alkaline manganese batteries (RAM) and lithium batteries. Boost charging has been found to be particularly advantageous for lithium batteries, including lithium ion batteries (Li-ion), lithium polymer batteries (Li-polymer), lithium polymer gel batteries (Li-polymer gel) and lithium-metal batteries (Li-metal), since lithium batteries must not be charged at high voltages. Due to this fact, any chargers for quick charging of lithium batteries did not exist hitherto.

The charger according to the invention may be a stand-alone charger or an integral charger. Thus the charger may be an integral part of any electronic or battery driven apparatus. Examples of such an electronic apparatus incorporating a charger are shavers, mobile phones, battery packs and personal computers. In the case of integral chargers a selector is preferably located at the housing of the apparatus, such as a shaver, to allow the user to choose the charging mode.

A number of tests were performed to demonstrate the effectiveness of the charger according to the invention. In the tests a Li-ion battery in the form of a standard Sony US18500 cell with a nominal capacity of 1100 mAh was used. All tests were performed at 25° C.

FIG. 2 shows the procedures of the boost charging and of the normal charging. The left vertical axis of FIG. 2 is the charge current I_(charge) in Amperes, the right vertical axis is the charging voltage V_(charge) in Volts and the horizontal axis is the charged battery capacity in mAh. Normal charging (dotted lines in FIG. 2) takes place at a constant current I_(const) of about 1 A until the battery has obtained about 80% of its maximum capacity. The control unit 6 comprises a charge current limiting function which increases the charge current from zero to the predetermined constant charging current I_(const) and then prevents the charging current from increasing any further. During this phase of constant current (CC) charging the charging voltage increases slowly from 3.6 to 4.2 V, which is the maximum charging voltage of this cell. When the charging voltage reaches 4.2 V the charger switches to constant voltage mode. Thus the cell is charged with the last 20% of its capacity at a constant voltage of 4.2 V and a decreasing current.

Boost charging is illustrated by means of solid lines in FIG. 2. At the start of the boost charging process an initial current I_(init) of 8 A is supplied to the cell. The charge voltage increases immediately, i.e. in less than I second, to the maximum charge voltage of 4.2 V. The control unit decreases the charging current such that the charging voltage is maintained at 4.2 V. The charging current first decreases rapidly, within 1 minute, to about 4 A. The charging current then decreases further at a slower rate.

As is indicated in FIG. 2, charging at the end of the charging process, i.e. the charging of the final 20% of the charging capacity, is similar for normal charging and boost charging. Thus it can be concluded that the impact of the high initial charging current on the charge build up is small.

In FIG. 3 the capacity build up as a function of time is shown. The vertical axis is the charged capacity, i.e. the capacity added to the battery during charging, in mAh and the horizontal axis is the time in minutes. The maximum charging voltage was 4.2 V. The dotted line describes the build up of charge in an empty battery using normal charging. After normal charging for 10 minutes the DoC of the battery has increased to about 16% of its maximum capacity. The constant current during the 10 minutes of normal charging was about 1 A corresponding to 1 A/1100 mAh=0.9 C-rates. Three tests were carried out with boost charging using an initial current I_(init) of 8 A corresponding to an initial C-rate of 8 A/1100 mAh 32 7.3 C-rates. The results of boost charging of an empty battery (0% initial DoC) and batteries with 10 and 25% initial DoC are shown by means of solid lines in FIG. 3. The empty battery obtained almost 50% of its maximum capacity after only 10 minutes of boost charging. The batteries that had an initial DoC of 10% and 25% respectively showed a somewhat slower capacity build up compared to the charging of the empty battery. However, as shown in FIG. 3, the capacity build up at boost charging was in all cases considerably quicker than capacity build up at normal charging.

In FIG. 4 the impact of the initial charging current I_(init) on the charging of an empty battery (0% initial DoC) to a certain DoC is demonstrated. The vertical axis is the initial charging current I_(init) in Amperes and the horizontal axis is the charging time in minutes. The curves denote the different DoC, 10-50%, at which charging is interrupted. Thus the 30% curve represents the time it takes to charge an empty battery to a DoC of 30% of its maximum capacity at different initial currents I_(init). The point P represents, by way of example, that, at an initial current I_(init) of 3 A, a DoC of 30% is reached after 6.9 minutes.

It is evident from FIG. 4 that an initial charging current I_(init) above 4 A, corresponding to an initial C-rate of about 3.6 C-rates, does not further decrease the time required to obtain a certain DoC. On the other hand an initial charging current below 2 A, corresponding to an initial C-rate of about 1.8 C-rates, results in a substantial increase of the time required to obtain a certain DoC.

A test was performed at a maximum charging voltage higher than the allowed 4.2 V. The maximum charging voltage was thus set to 4.3 V. It was found that an empty battery (0% initial DoC) was charged to a DoC of almost 50% at an initial charging current I_(init) of 8 A in 8 minutes which is two minutes less than the 10 minutes required at 4.2 V (see FIG. 3).

The present invention provides a quick charging method and a charger for the quick charging of all types of batteries, including lithium batteries, by applying a high initial charging current such that the charging voltage is at its maximum predetermined value during substantially all of the charging process. The first minutes of charging thus occur at a very high current, causing charge to be added very quickly to the battery. By charging the battery only partially the time needed for charging is decreased and so is the detrimental effect on the cycle life of the battery.

Finally, to summarize, a battery charger for charging rechargeable batteries and/or battery packs is disclosed. Preferably the charger can apply two modes of charging a battery. In a normal charging mode a battery is charged to full capacity at a low rate. In a boost charging mode the battery is charged very rapidly and preferably only to a certain degree, such as 75% of its maximum capacity. The boost charging mode makes it possible to supply some charge to the battery when the time available for charging is limited. The boost charging method is based on a very high initial charging current I_(init). The initial current I_(init) is such that a predetermined maximum charging voltage V_(max) is reached almost immediately. The charging current is then decreased in such a way that the charging voltage V_(charge) is maintained substantially constant at the maximum charging voltage V_(max). 

1. A method of charging a rechargeable unit, such as a rechargeable battery or a rechargeable battery pack, characterized in: that the rechargeable unit is connected to a supply unit; that the supply unit supplies a current to the rechargeable unit; that the charging voltage is monitored during charging; that the initial current supplied to the rechargeable unit at the start of the charging process is such that the charging voltage almost immediately reaches a predetermined maximum charging voltage; and that subsequently the current is decreased in such a way that the charging voltage is kept substantially constant at the maximum charging voltage during the charging process.
 2. A method according to claim 1, wherein the initial charging current is such that the charging voltage reaches the predetermined maximum charging voltage within 2 minutes at most.
 3. A method according to claim 1, wherein the initial charging current corresponds to more than 1 C-rate.
 4. A method according to claim 1, wherein the rechargeable unit is charged to maximally 75% of its maximum capacity, the charging process then being interrupted.
 5. A method according to claim 1, wherein the initial depth of charge of the rechargeable unit to be charged is measured before charging starts or at the beginning of the charging process, charging being stopped if the rechargeable unit is found to have an initial depth of charge which is higher than a predetermined maximum initial depth of charge.
 6. A method according to claim 1, wherein the rechargeable unit comprises a lithium battery.
 7. A charger for charging a rechargeable unit, such as a rechargeable battery or a rechargeable battery pack, comprises: a supply unit for supplying charging current to a rechargeable unit; terminals for connecting the supply unit to the rechargeable unit; and a control unit for controlling the current supplied by the supply unit, characterized in that the charger further comprises: means for monitoring the charging voltage; means for supplying an initial charging current at the start of the charging process of a rechargeable unit, the initial charging current being such that the charging voltage supplied to the rechargeable unit almost immediately reaches a predetermined maximum charging voltage; and means for decreasing the current in such a way that the charging voltage is kept substantially constant at the maximum charging voltage during the charging process.
 8. A charger according to claim 7, wherein the control unit comprises a selector for choosing between: a boost charging mode wherein the control unit is adapted to make the supply unit supply an initial current at the start of the charging process of a rechargeable unit, the initial charging current being such that the charging voltage supplied to the rechargeable unit almost immediately reaches a predetermined maximum voltage; and a normal charging mode wherein the control unit is adapted to make the supply unit supply a constant charging current at the start of the charging process of a rechargeable unit, the constant charging current being such that the rechargeable unit is charged with a substantial capacity at said constant current before the charging voltage reaches a predetermined maximum voltage.
 9. A charger according to claim 7, wherein the control unit comprises means for measuring the depth of charge of the rechargeable unit during charging and means for interrupting the charging procedure at a predetermined depth of charge.
 10. A charger according to claim 7, wherein the charger comprises a timer function for interrupting the charging process after a predetermined time interval. 